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Old 08-17-2015, 06:42 PM   #31
MrBoooots
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Default Re: 1983 EZGO rarely start?? Need help....

No I cant seem to get them off... that's why I cant remove the housing around crank shaft, something I'm missing?
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Old 08-17-2015, 06:53 PM   #32
MrBoooots
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Default Re: 1983 EZGO rarely start?? Need help....

Ill take a pic so you can see where I'm at...
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Old 08-17-2015, 06:57 PM   #33
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Default Re: 1983 EZGO rarely start?? Need help....

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Old 08-17-2015, 06:57 PM   #34
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Default Re: 1983 EZGO rarely start?? Need help....

To remove the clutch take out the long center bolt. You will need a short rod to sit on top of those threads. You then screw a 3/4" fine thread bolt on top of the rod to press off the clutch. An air impact works best, but it's possible to use a breaker bar, and hope for the best.

This is what you need to remove the flywheel. You can buy them anywhere.
http://www.harborfreight.com/bolt-ty...set-69889.html

The one I bought happened to have a 3/4" fine thread bolt for the center, so it was a bonus for me. The flywheel has two 6 mm bolt holes that you screw into with the puller. Be careful to not hit the pulsar underneath while installing those bolts.

There is no need to split the case halves to remove the seals. Puncture the metal part of the seal. Do not drill a hole. Use a sharp punch. Screw a sheet metal, or drywall screw into the hole. A slide hammer would be real nice now to yank the seals out, but you should be able to find some vice grips, or something to give a good yank.

EDIT: Make sure you don't get any junk down into the case that could destroy the bearings, or else you will do all of the work twice.

Install the new ones with green Loctite. I also staked mine with a hammer and punch after they popped out once.
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Old 08-17-2015, 06:57 PM   #35
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Default Re: 1983 EZGO rarely start?? Need help....

http://postimg.org/image/j6vls9223/14ab7b95/
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Old 08-17-2015, 07:01 PM   #36
MrBoooots
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Default Re: 1983 EZGO rarely start?? Need help....

Ok, I have parts ordered now. New gaskets and 2 crankshaft seals. Ill post again once they get here and are installed. Thanks again for all the help, had no idea so many people were playing with these old things...
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Old 08-17-2015, 07:52 PM   #37
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Default Re: 1983 EZGO rarely start?? Need help....

While we are waiting for parts, let's discuss the 3 sets of bearings on the crankshaft.
My engine was sitting about the same way as yours. My bearings, piston, and rings were all in great shape.
I cleaned everything up, replaced the seals, and gaskets, then put it all back together.

It fired right up, and ran great for a day or so. As I was riding, it just stopped dead. The engine was seized.

I took it apart AGAIN, split the cases, and found that something got into the lower end, and destroyed one bearing. When that bearing came apart, it pushed the next bearing up against the crankshaft lobe really tight. That's why it locked up.

I took the crankshaft to work. There we were, three highly skilled airline mechanics with top of the line tools, and a world class machine shop at our disposal, struggling with getting that bearing race from against the crankshaft lobe. It took us an hour to finally get it off without doing any damage.

I'm telling you this so that you understand how important it is to make sure nothing gets into the lower end. It's especially important if you don't have access to those kinds of resources.
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